Method of determining a position of an actuator

ABSTRACT

An encoding sequence is configured to detect the position and direction of motion of an actuator. The actuator includes at least two members where one of the members moves with respect to the other. Two sets of binary indicators are either affixed to or integrally assembled along one of the members. Each pair of indicators defines a position of the actuator and each binary indicator is configured to identify one of two states, such as a magnetic pole or a graphical mark where each state corresponds to a logical zero or a logical one. The indicators are arranged on the actuator such that at least one of the indicators transitions between one of the two states at each position along the actuator. At least one sensor is provided to detect the state of the binary indicators as the two members of the actuator move with respect to each other.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a divisional of application Ser. No.13/655,122 filed Oct. 18, 2012.

BACKGROUND OF THE INVENTION

The subject matter disclosed herein relates generally to an apparatusfor detecting position, and in particular, to an encoding sequence todetect the position and direction of motion of an actuator.

As is known, actuators are controlled devices that transfer energy froma source to an object to induce operation of that object. Actuators maybe driven, for example, by a variety of sources including, but notlimited to, electrical, hydraulic, or pneumatic. In response to energyfrom the source, the actuator may generate a rotational or linear forceto drive, for example, a ball screw or a piston. In some applications,the actuator may simply turn on or off and may be controlled by limitswitches or positive stops at the end of travel. In other applications,it is desirable to have more precise control of the actuator, requiringknowledge of the current position of the actuator.

Historically, numerous encoding schemes have been used to obtain thecurrent position of an actuator. If the actuator is driven by arotational force, such as a motor, a rotational position sensor such asan encoder or resolver may be attached to the motor. Knowledge of theangular position of the motor is converted to a corresponding positionof the actuator. If the actuator is driven by a linear force, such as ahydraulic cylinder, a linear position sensor may be attached to thecylinder to obtain a position measurement.

Numerous encoding techniques have been employed in conjunction with theposition sensors to obtain the desired position information. Aphysically detectable pattern may be affixed to or integrally assembledon the actuator. A sensor head is provided to detect the pattern andgenerate signals corresponding to the pattern. One such pattern utilizesmultiple bits at each position that provide a unique identifier, ornumber, for each position. The number may represent a binary codednumber or another number encoded according to another scheme, such asGray code. However, as the length of travel of the actuator and/or thedesired precision increases, the number of bits required to identifyeach of the positions also increases. The sensor head and accompanyingcontrol electronics must be configured to read and to process theincreased number of bits. Thus, it would be desirable to provide anencoding sequence that utilizes a reduced number of bits to define eachof the positions over the length of travel of the actuator.

Whether rotational or linear, the position sensors may be furtherclassified as incremental or absolute. An incremental sensor starts atzero upon power up and maintains a record of movement of the actuator ineither a positive or negative direction from the initial position. Aknown reference point, or home position, may also be used to reset theincremental sensor and subsequently control motion of the actuator fromthe known reference point. An absolute position sensor is similarlyreset to a known reference point during initial configuration; however,the absolute position sensor maintains knowledge of the current positionwhen power to the sensor is cycled.

In order to maintain knowledge of the current position, either staticmemory (i.e., data is retained during a power cycle) is required or theencoding sequence must provide a unique sequence of data at eachposition. However, each of these implementations has certaindisadvantages. Static memory is not effective if there is potential formovement of the actuator while power is off in which case the retainedvalue will not be correct upon power up. Providing a unique identifierfor each position may require an increased number of bits for eachidentifier and related circuitry to read each bit. Thus, it would bedesirable to provide an encoding sequence from which the currentposition of the actuator may be determined upon power up whilemaintaining a reduced number of bits to define each of the positionsover the length of travel of the actuator.

SUMMARY OF THE INVENTION

The present invention relates to an encoding sequence to detect theposition and direction of motion of an actuator. The actuator includesat least two members where one of the members moves with respect to theother. Two sets of binary indicators are either affixed to or integrallyassembled along one of the members. Each pair of indicators defines aposition of the actuator and each binary indicator is configured toidentify one of two states, such as the presence or absence of a mark ora magnetic north or south pole, and each state corresponds to a logicalzero or a logical one. The indicators are arranged on the actuator suchthat at least one of the binary indicators transitions between one ofthe two states at each position along the actuator. At least one sensoris provided to detect the state of the binary indicators as the twomembers of the actuator move with respect to each other.

According to a first embodiment of the invention, a method for detectinga position of an actuator having a first set of binary indicatorsaffixed to the actuator and a second set of binary indicators affixed tothe actuator is disclosed. Each of the indicators in the first andsecond sets of binary indicators defines a bit, and each of the firstand second sets of binary indicators has a predefined word length equalto multiple bits. The method includes the steps of moving the actuator adistance corresponding to the word length of each set of the binaryindicators, sensing the first and second sets of binary indicators whilemoving the actuator, and determining the position of the actuator as afunction of the first and second sets of binary indicators. Sensing thefirst and second sets of binary indicators may further include the stepsof detecting a change of state in each of the first and second sets ofbinary indicators, generating a first signal corresponding to the changein state in the first set of binary indicators; and generating a secondsignal corresponding to the change in state of the second set of binaryindicators. At least one of the first and second sets of binaryindicators changes state at each position. The method may furtherinclude the step of determining a direction of motion of the actuator asa function of the first and second signals.

According to another aspect of the invention, the word length for eachof the first set and second set of binary indicators may be defined by afirst start bit, a second start bit, and a plurality of data bits. Thefirst and second start bits of the first set of binary indicators may beset equal to each other. For, the second set of binary indicators, oneof the first and second start bits may be set to a logical one and theother of the first and second start bits may be set to a logical zero.

According to still another aspect of the invention, the word length foreach of the first set and second set of binary indicators may be definedby a first start bit and a plurality of data bits. For the first set ofbinary indicators, the start bit may be set equal to the first data bitand the remaining data bits alternate from the previous data bit. Forthe second set of binary indicators, the start bit may be set oppositeto the first data bit.

According to yet another aspect of the invention, the word length foreach of the first set and second set of binary indicators may be definedby a first start bit, a second start bit, a third start bit, and aplurality of data bits. Each of the first, second, and third start bitsof the first set of binary indicators may be set equal to the bitpreceding the respective start bit, and each of the first, second, andthird start bits of the second set of binary indicators may be setopposite to the bit preceding the respective start bit.

According to another embodiment of the invention, a system for detectinga position of an actuator having a first member and a second membermovable with respect to the first member includes a first set of binaryindicators located on the first member of the actuator. The first set ofbinary indicators has a predefined word length, each binary indicatordefines one bit within the word, and each binary indicator defines aposition of the first member with respect to the second member. A secondset of binary indicators is also located on the first member of theactuator. Each of the binary indicators in the second set corresponds toone of the binary indicators in the first set. At least one sensor isconfigured to generate a first signal corresponding to the state of thefirst set of binary indicators and to generate a second signalcorresponding to the state of the second set of binary indicators. Alogic circuit is configured to receive each of the signals correspondingto the state of the first and second set of binary indicators and todetect the position of the first member of the actuator with respect tothe second member.

According to another aspect of the invention, a first sensor may beconfigured to detect the state of the first set of binary indicators andto generate the first signal corresponding to the state of the first setof binary indicators, and a second sensor may be configured to detectthe state of the second set of binary indicators and to generate thesecond signal corresponding to the state of the second set of binaryindicators. The first signal may identify a change of state of thebinary indicators between adjacent positions in the first set of binaryindicators, and the second signal may identify a change of state of thebinary indicators between adjacent positions in the second set of binaryindicators.

According to still another aspect of the invention, the first set ofbinary indicators may include a first start bit set to one of a firststate or a second state and a second start bit set to the same state asthe first start bit. The second set of binary indicators may include afirst start bit set to one of the first state or the second state and asecond start bit set to the opposite state of the first start bit.

According to yet another aspect of the invention, the first set ofbinary indicators may include a start bit set to one of a first stateand a second state and a plurality of data bits. Each data bit of thefirst set of binary indicators is set to one of the first state and thesecond state, and the start bit is set to the same state as the firstdata bit from the plurality of data bits. The second set of binaryindicators may include a start bit set to one of a first state and asecond state and a plurality of data bits. Each data bit of the secondset of binary indicators bit may be set to one of the first state andthe second state, and the start bit is set to the opposite state as thefirst data bit from the plurality of data bits.

According to another aspect of the invention, the first set of binaryindicators may includes a first start bit set to one of a first stateand a second state, a second start bit set to one of the first state andthe second state, and a third start bit set to one of the first stateand the second state. The second set of binary indicators may include afirst start bit set to one of the first state and the second state, asecond start bit set to one of the first state and the second state, anda third start bit set to one of the first state and the second state.Each of the first, second, and third start bits of the first set ofbinary indicators is set to the same state as the bit preceding therespective start bit, and each of the first, second, and third startbits of the second set of binary indicators is set to the opposite stateas the bit preceding the respective start bit.

According to still other aspects of the invention, each of the binaryindicators may be magnetic regions. A magnetic north pole corresponds toone of a logical zero or logical one, and a magnetic south polecorresponds to the other of the logical zero or logical one. Optionally,the presence of either a magnetic north or south pole corresponds to oneof a logical zero or logical one and the absence of the pole correspondsto the other of a logical zero or logical one Each of the binaryindicators may be one of a raised portion or a recessed portion. One ofthe raised portion or the recessed portion corresponds to one of alogical zero or logical one, and the other of the raised portion or therecessed portion corresponds to the other of the logical zero or logicalone. Each of the binary indicators may be the presence or absence of amark. One of the presence or absence of the mark corresponds to one of alogical zero or logical one, and the other of the presence or absence ofthe mark corresponds to the other of a logical zero or logical one.

According to still another embodiment of the invention, a method ofdetermining a position of an actuator using a first set of binaryindicators and a second set of binary indicators is disclosed. Each ofthe first and second sets of binary indicators has a predefined wordlength. The method includes the steps of defining a plurality ofpositions along the range of motion of the actuator, assigning a binaryindicator from the first set of binary indicators to each of theplurality of positions, assigning a binary indicator from the second setof binary indicators to each of the plurality of positions, anddetecting a change in state for each set of binary indicators betweenadjacent positions for a number of adjacent positions equal to thepredefined word length. At least one of the first and second sets ofbinary indicators changes states between each adjacent position.

Other objects, features, aspects, and advantages of the invention willbecome apparent to those skilled in the art from the following detaileddescription and accompanying drawings. It should be understood, however,that the detailed description and specific examples, while indicatingpreferred embodiments of the present invention, are given by way ofillustration and not of limitation. Many changes and modifications maybe made within the scope of the present invention without departing fromthe spirit thereof, and the invention includes all such modifications.

BRIEF DESCRIPTION OF THE FIGURES

Preferred exemplary embodiments of the invention are illustrated in theaccompanying drawings in which like reference numerals represent likeparts throughout.

In the drawings:

FIG. 1 is a perspective view of an exemplary hydraulic cylinderincorporating the encoding sequence of the present invention accordingto one embodiment of the invention;

FIG. 2 is a perspective view of an exemplary hydraulic cylinderincorporating the encoding sequence of the present invention accordingto another embodiment of the invention;

FIG. 3 is a block diagram representation of a controller used with thehydraulic cylinder of FIG. 1;

FIG. 4 is a graphical representation of the encoding sequence accordingto one embodiment of the present invention having an even word length;

FIG. 5 is a graphical representation of the encoding sequence accordingto one embodiment of the present invention having an odd word length;

FIG. 6 is a graphical representation of the encoding sequence accordingto another embodiment of the present invention having an odd wordlength;

FIG. 7 is a graphical representation of the encoding sequence accordingto another embodiment of the present invention having an even wordlength;

FIG. 8 is a graphical representation of the encoding sequence accordingto still another embodiment of the present invention having an odd wordlength; and

FIG. 9 is a graphical representation of the encoding sequence accordingto still another embodiment of the present invention having an even wordlength.

DETAILED DESCRIPTION

The various features and advantageous details of the subject matterdisclosed herein are explained more fully with reference to thenon-limiting embodiments described in detail in the followingdescription.

Referring to FIGS. 1-2, a hydraulic cylinder 10 is an exemplary actuatorincorporating one embodiment of the encoding sequence according to thepresent invention. The hydraulic cylinder 10 includes a barrel 12,having a first end 14 and a second end 16, and a rod 18, having a firstend 20 and a second end 22. The first end 14 of the barrel 12 and thesecond end 22 of the rod 18 are configured to be mounted to an object onwhich the cylinder is configured to operate. The first end 20 of the rod18 slidably engages the second end 16 of the barrel 12 and moves betweena fully retracted position and a fully extended position. The length Lof the rod 18 is divided into multiple segments. Each segment defines aposition 32 of the rod 18 between the fully retracted and fully extendedpositions.

An encoding sequence is applied along the rod 18 of the hydrauliccylinder 10 to identify each of the positions 32 along the rod 18. Theencoding sequence includes a first set of binary indicators 25 and asecond set of binary indicators 30. A binary indicator as used herein isdefined as a device that indicates one of two states, including, but notlimited to, on or off, present or absent, zero or one, and north orsouth. Suitable binary indicators include, for example, the presence orabsence of a marking, the north or south pole of a magnet, and thepresence or absence of a raised member or recessed section. For eachposition 32 defined along the rod 18, each set of binary indicators 25,30 will have an indication of one of the two states used by the binaryindicator. Thus, each position 32 is identified by an identifier havingjust two bits (i.e., one bit from the first set of binary indicators 25and one bit from the second set of binary indicators 30).

Each set of binary indicators 25, 30 is oriented to be sequentiallydetected as the actuator moves. As illustrated, the first and second setof binary indicators 25, 30, respectively, are linearly positioned alongthe length L of the rod 18. Optionally, the binary indicators may bepositioned around the periphery of a rotating actuator. According tostill another embodiment, the binary indicators may be positioned alonga stationary member and a sensor head affixed to a moving member of theactuator. At least one sensor head 35 detects each of the binaryindicators. In one embodiment of the invention, a single sensor head 35detects both of the first and second set of binary indicators 25, 30,respectively. The sensor head 35 generates a signal corresponding to thestate of the binary indicator in each of the sets of indicators 25, 30at each position 32. According to another embodiment of the invention,two sensor heads 35 are provided. The first sensor head 35 detects thestate of the binary indicator for the first set of binary indicators 25at each position 32, and the second sensor head 35 detects the state ofthe binary indicator for the second set of binary indicators 30 at eachposition 32. Each sensor head 35 generates the signal corresponding tothe state of the binary indicator from its corresponding set ofindicators 25, 30. The signal is transferred to a suitable logic circuit50, see also FIG. 3, via a cable 40 electrically connected to the sensorhead 35.

Referring next to FIG. 3, an exemplary logic circuit 50 configured toreceive signals from the sensor head 35 is illustrated. According to oneembodiment of the invention, the logic circuit 50 includes a processor54 in communication with a memory device 56. The memory device 56 storesa series a program which includes a series of instructions executable bythe processor 54. The processor 54 is in communication with a port 52which may be external to or integral with the processor 54. The port 52is configured to receive each of the first and second signals from thesensor head 35. The program may further include instructions executableby the processor 54 to control the actuator 10 as a function of thesignals from the sensor head 35. The processor 54 and memory 56 may beseparate devices or integrated, for example, on a field programmablegate array (FPGA) or an application specific integrated circuit (ASIC).According to another embodiment of the invention, discrete logicelements may be used to receive and process the signals from the sensorhead 35. Optionally, a portion of or the entire logic circuit 50 may beintegrated into the sensor head 35 and outputs corresponding to positionand/or direction of motion may be output to an external device.

Referring next to FIGS. 4 and 5, an encoding sequence according to afirst embodiment of the invention is illustrated. The first set ofbinary indicators 25 is also identified as the clock sequence CLK, andthe second set of binary indicators 30 is also identified as the datasequence DATA. FIG. 4 illustrates an encoding sequence in which the wordlength 24 is an even number, and FIG. 5 illustrates an encoding sequencein which the word length 24 is an odd number. As illustrated, the wordlength 24 of FIG. 4 for each set of indicators 25, 30 is six, containingtwo start bits 26 (i.e., S0 and S1) and four data bits 28 (i.e., B0, B1,B2, and B3), and the word length 24 of FIG. 5 for each set of indicators25, 30 is seven, containing two start bits 26 (i.e., S0 and S1) and fivedata bits 28 (i.e., B0, B1, B2, B3, and B4). Each of the start bits 26in the first set of binary indicators 25 are set equal to each other.The data bits 28 in the first set of binary indicators 25 are then setto the opposite state of the preceding bit. The first start bit S0 ofthe next word is set to the opposite state of the preceding data bit.For an even word length 24, the start bits 26 in the first set of binaryindicators 25 will, therefore, alternately be set to a one-onecombination and a zero-zero combination. For an odd word length 24, thestart bits 26 in the first set of binary indicators 25 will always beset to the same combination, either a one-one or a zero-zerocombination. The two start bits 26 in the second set of binaryindicators 30 are set to either a one-zero combination or a zero-onecombination such that the two start bits 26 are of an opposite statefrom each other. The data bits 28 of the second set of binary indicators30 define binary numbers between zero and 2^(n)−1 where “n” is thenumber of data bits 28 present in the second set of binary indictors 30.

Referring next to FIGS. 6 and 7, an encoding sequence according toanother embodiment of the invention is illustrated. The first set ofbinary indicators 25 is again identified as the clock sequence CLK, andthe second set of binary indicators 30 is again identified as the datasequence DATA. FIG. 6 illustrates an encoding sequence in which a wordlength 24 is an odd number, and FIG. 7 illustrates an encoding sequencein which the word length 24 is an even number. As illustrated, the wordlength 24 of FIG. 6 for each set of indicators 25, 30 is five,containing one start bit 26 (i.e., S0) and four data bits 28 (i.e., B0,B1, B2, and B3), and the word length 24 of FIG. 7 for each set ofindicators 25, 30 is six, containing one start bit 26 (i.e., S0) andfive data bits 28 (i.e., B0, B1, B2, B3, and B4). In the first set ofbinary indicators 25, the start bit 26 is set equal to the first databit 28. Each of the data bits 28 beyond the first data bit 28 in thefirst set of binary indicators 25 are then set to the state opposite thestate of the preceding bit. The start bit S0 of the next word is set tothe opposite state of the preceding data bit. For an odd word length 24,the start bit 26 and the first data bit 28 in the first set of binaryindicators 25 will always be set to the same combination, either aone-one or a zero-zero combination. For an even word length 24, thestart bit 26 and the first data bit 28 in the first set of binaryindicators 25 will alternately be set to a one-one combination and azero-zero combination. The start bit 26 in the second set of binaryindicators 30 is set to the opposite state of the first data bit 28. Thedata bits 28 of the second set of binary indicators 30 define binarynumbers between zero and 2^(n)−1 where “n” is the number of data bits 28present in the second set of binary indictors 30.

Referring next to FIGS. 8 and 9, an encoding sequence according to yetanother embodiment of the invention is illustrated. The first set ofbinary indicators 25 is again identified as the clock sequence CLK, andthe second set of binary indicators 30 is again identified as the datasequence DATA. FIG. 8 illustrates an encoding sequence in which a wordlength 24 is an odd number, and FIG. 9 illustrates an encoding sequencein which the word length 24 is an even number. As illustrated, the wordlength 24 of FIG. 8 for each set of indicators 25, 30 is seven,containing three start bits 26 (i.e., S0, S1, and S2) and four data bits28 (i.e., B0, B1, B2, and B3), and the word length 24 of FIG. 9 for eachset of indicators 25, 30 is eight, containing three start bits 26 (i.e.,S0, S1, and S2) and five data bits 28 (i.e., B0, B1, B2, B3, and B4). Inthe first set of binary indicators 25, each of the start bits 26 is setequal to the preceding bit. The initial start bit (i.e., S0 of the firstword) may be selected as either a zero or a one. For an odd word length,the start bits 26 repeat in the same combination (zero-zero-one orone-one-zero). For an even word length, the start bits 26 repeat in analternating manner between zero-zero-one and one-one-zero. In the firstset of binary indicators 25, each of the data bits 28 is set to theopposite state of the preceding bit. In the second set of binaryindicators 30, the start bits 26 are opposite the preceding bit. Thedata bits 28 of the second set of binary indicators 30 define binarynumbers between zero and 2^(n)−1 where “n” is the number of data bits 28present in the second set of binary indictors 30.

In operation, the encoding sequence is used to detect the currentposition of an actuator. The encoding sequence permits the logic circuit50 to determine the current position of the actuator by moving theactuator for a distance corresponding to a number of positions 32 equalto the word length 24 of the sets of binary indicators 25, 30. Asdiscussed in more detail below, the positions 32 across which theactuator moves need not correspond to a single word, but may span aportion of two adjacent words. Thus, the logic circuit 50 may rapidlydetermine the current position upon power up without requiring that theposition be stored when power is cycled and without requiring a uniqueidentifier for each position. Further, the logic circuit 50 does notrequire that the start of a word first be identified and thensubsequently require moving the actuator for a distance corresponding tothe word length 24. The encoding sequence, therefore, determines theposition using only two bits per position 32, namely one bit from thefirst set of binary indicators 25 and one bit from the second set ofbinary indicators 30.

The logic circuit 50 is configured to determine the position of theactuator as a function of the signals corresponding to the current stateof each of the sets of binary indicators 25, 30. Referring again toFIGS. 4 and 5, transitions in state for the first set of binaryindicators 25 when the actuator is moving in the forward direction, FWD,and the reverse direction, REV are shown by reference numerals 27 and29, respectively. Transitions in state for the second set of binaryindicators 30 when the actuator is moving in the forward direction, FWD,and the reverse direction, REV are shown by reference numerals 31 and33, respectively. As the actuator is moving forward, the first set ofbinary indicators 25 changes state between each successive position 32except for the transition between the first and second start bits 26.During this transition between positions 32 in which the first set ofbinary indicators 25 does not change state, the start bits 26 of thesecond set of binary indicators 30 do change state. Thus, the logiccircuit 50 detects a change in state for each transition betweenpositions 32.

Based on the sensed changes in state, the logic circuit 50 may thendetermine the current position of the actuator. The word length 24 isstored in the logic circuit 50. Because the logic circuit 50 detects achange in state in at least one of the sets of binary indicators 25, 30at each transition between positions 32 along the actuator, the logiccircuit 50 detects when the actuator has moved a number of positions 32equal to the word length 24. As the actuator is moving, the state ofeach of the binary indicators in the first and second set of binaryindicators 25, 30 is stored. The current position 32 may then beobtained by reconstructing the stored data bits 28 from the second setof binary indicators to identify a binary coded number. For example, inFIG. 4, the number may range from 0-15 with four data bits 28 or from0-31 in FIG. 5 with five data bits 28. This reconstructed binary number,in combination with the stored start bits 26, will identify the currentposition 32 of the actuator.

Further, the logic circuit 50 identifies a specific location within theword as a function of the start bits 26 of the first and second set ofbinary indicators 25, 30. As illustrated in the forward and reverse rows27, 29 of the tables in FIGS. 4 and 5, the first set of binaryindicators 25 transitions at every position except between the two startbits 26. The logic circuit 50, therefore, identifies between which twobits within the first set of binary indicators 25 that no transition wasobserved to identify which bits within the word are the start bits 26.In addition, one of the start bits 26 of the second set of binaryindicators 30 is always set to one state, for example, zero and theother of the start bits 26 of the second set of binary indicators 30 isalways set to the other state, for example, one. As a result, the logiccircuit 50 may evaluate the states of the start bits 26 of the secondset of binary indicators 30 to determine which of the two start bits 26is the first start bit, S0, and which is the second start bit, S1.

Based on the sensed transitions in state, the logic circuit 50 may alsodetermine the direction of travel of the actuator. As previouslyindicated, the start bits 26 of the first and second set of binaryindicators 25, 30 have a unique relationship. The transition between thetwo start bits 26 is the only point at which no change of state occursin the first set of binary indicators 25. The two start bits 26 in thesecond set of binary indicators 25 are predefined as either a zero-onecombination or a one-zero combination. By observing the state of thebits in the second set of binary indicators 30 when no transition in thefirst set of binary indicators 25 occurs, the direction of travel of theactuator is identified. As illustrated in FIG. 4, if the actuator ismoving forward, no transition in the first set of binary indicators 25is identified at the second start bit, S1, and the second start bit, S1,of the second set of binary indicators 30 is always zero. In contrast,if the actuator is moving in reverse, no transition in the first set ofbinary indicators 25 is identified at the first start bit, S1, and thefirst start bit, S1, of the second set of binary indicators 30 is alwaysone.

According to another embodiment of the invention, the logic circuit 50may be configured to determine the position of the actuator using asingle start bit 26. As the actuator is moving forward, the first set ofbinary indicators 25 changes state between each successive position 32except for the transition between the start bit 26 and the first databit 28. During this transition between positions 32 in which the firstset of binary indicators 25 does not change state, the second set ofbinary indicators 30 does change state. Thus, the logic circuit 50detects a change in state for each transition between positions 32.Based on the sensed changes in state, the logic circuit 50 may thendetermine the current position of the actuator. The word length 24 isstored in the logic circuit 50. Because the logic circuit 50 detects achange in state in at least one of the sets of binary indicators 25, 30at each transition between positions 32 along the actuator, the logiccircuit 50 detects when the actuator has moved a number of positions 32equal to the word length 24. As the actuator is moving, the state ofeach of the binary indicators in the first and second set of binaryindicators 25, 30 is stored. The current position 32 may then beobtained by reconstructing the stored data bits 28 from the second setof binary indicators to identify a binary coded number. For example, inFIG. 6, the number may range from 0-15 with four data bits 28 or from0-31 in FIG. 7 with five data bits 28. This reconstructed binary number,in combination with the stored start bit 26, will identify the currentposition 32 of the actuator.

The logic circuit 50 may also be configured to determine the directionof travel of the actuator using a single start bit 26. However, if onlya single start bit 26 is used in the encoding sequence, the overall wordlength 24 must be an even number. As illustrated in the forward andreverse rows 27, 29 of FIG. 7, the first set of binary indicators 25 hasa change of state at every position except between the start bit 26 andthe first data bit 28. The logic circuit 50, therefore, identifies thistransition during which the first set of binary indicators 25 does notchange state. The logic circuit 50 further identifies whether the startbit 26 and first data bit 28 were either a one-one combination or azero-zero combination. The logic circuit 50 further identifies the stateof the start bit 26 and the first data bit 28 of the second set ofbinary indicators 30. When the actuator is moving forward, the start bit26 and the first data bit 28 of the second set of binary indicators 30will be a one-zero combination if the start bit 26 and the first databit 28 of the first set of binary indicators 25 are a one-onecombination, and the start bit 26 and the first data bit 28 of thesecond set of binary indicators 30 will be a zero-one combination if thestart bit 26 and the first data bit 28 of the first set of binaryindicators 25 are a zero-zero combination. In contrast, when theactuator is moving in reverse the start bit 26 and the first data bit 28of the second set of binary indicators 30 will be a zero-one combinationif the start bit 26 and the first data bit 28 of the first set of binaryindicators 25 are a one-one combination, and the start bit 26 and thefirst data bit 28 of the second set of binary indicators 30 will be aone-zero combination if the start bit 26 and the first data bit 28 ofthe first set of binary indicators 25 are a zero-zero combination. As aresult, the logic circuit 50 may evaluate the start bit 26 and the firstdata bit 28 of both the first and second set of binary indicators 25, 30to determine the direction of motion of the actuator when the encodingsequence includes a single start bit 26 and has an even word length 24.

In an alternate embodiment of the invention, the sensor head 35 may beunable to provide the current state of one of the binary indicators butrather be able to provide only an indication of a change in statesbetween adjacent indicators. As illustrated in FIGS. 8 and 9, anencoding sequence employing three start bits 26 (i.e., S0, S1, and S2)may be used to detect the current position of the actuator using onlyinformation regarding the change in state of the binary indicatorsbetween adjacent positions 32. Each word begins with two start bits S0,S1. The two start bits S0, S1 are followed in sequence by the first databit B0, the third start bit S2, and the remaining data bits. Each bit ofthe first set of binary indicators 25 is configured to produce anasymmetrical pattern of changes in state for the word length 24. As theactuator moves in the forward direction, there is no change of statebetween a prior binary indicator and a start bit 26. In contrast, thereis a change of state between a prior binary indicator and each data bit28. As illustrated by the forward transitions 27 of the first set ofbinary indicators 25, each of the start bits 26 are identified by a zeroand each of the data bits 28 are identified by a one. In contrast, theforward transitions 31 of the second set of binary indicators 30 isconfigured to generate a one for each of the start bits 26 and a binaryencoded number for the data bits 28. The current position 32 may then beobtained by reconstructing the changes of state in the second set ofbinary indicators 30 corresponding to data bits 28 to identify a binarycoded number. For example, in FIG. 8, the number may range from 0-15with four data bits 28 or from 0-31 in FIG. 9 with five data bits 28.This reconstructed binary number, in combination with the changes ofstate for the start bits 26, will identify the current position 32 ofthe actuator.

Based on the sensed transitions in state, the logic circuit 50 may alsodetermine the direction of travel of the actuator. As previouslyindicated, the changes in state between adjacent bits for the first setof binary indicators 25 results in a zero-zero combination for the firsttwo start bits S0, S1 a single zero at the third start bit S2, and asingle one between the two sets of start bits for the first data bit B0.As the logic circuit 50 monitors the changes of state for the first setof binary indicators 25, the pair of zeros occurs prior to the singlezero in the forward direction 27 but the pair of zeros occurs after thesingle zero in the reverse direction 29. Consequently, the logic circuit50 may monitor the changes in state of the start bits 26 correspondingto the first set of binary indicators 25 to identify the direction theactuator is moving.

It should be understood that the invention is not limited in itsapplication to the details of construction and arrangements of thecomponents set forth herein. The invention is capable of otherembodiments and of being practiced or carried out in various ways.Variations and modifications of the foregoing are within the scope ofthe present invention. It also being understood that the inventiondisclosed and defined herein extends to all alternative combinations oftwo or more of the individual features mentioned or evident from thetext and/or drawings. All of these different combinations constitutevarious alternative aspects of the present invention. The embodimentsdescribed herein explain the best modes known for practicing theinvention and will enable others skilled in the art to utilize theinvention.

I claim:
 1. A method of determining a position of an actuator, theactuator having a first member axially movable with respect to a secondmember, comprising the steps of: axially spacing a first set of binaryindicators located in a first plane along the first member of theactuator, the first set of binary indicators has a predefined wordlength; axially spacing a second set of binary indicators located in asecond plane along the first member of the actuator, the second set ofbinary indicators has a predefined word length; positioning a sensor ata location radially spaced from the first actuator; defining a pluralityof positions along the range of motion of the actuator; assigning abinary indicator from the first set of binary indicators to each of theplurality of positions; assigning a binary indicator from the second setof binary indicators to each of the plurality of positions; detectingwith the sensor a change in state for each set of binary indicatorsbetween adjacent positions for a number of adjacent positions equal tothe predefined word length, wherein at least one of the first and secondsets of binary indicators changes states between each adjacent position;generating a first signal corresponding to the change of state of thefirst set of binary indicators and generating a second signalcorresponding to the change of state of the second set of binaryindicators with the sensor; and determining the position of the actuatoras a function of the first and second signals.
 2. The method of claim 1wherein: the word length for each of the first set and second set ofbinary indicators is defined by a first start bit, a second start bit,and a plurality of data bits; the first and second start bits of thefirst set of binary indicators are set equal to each other; one of thefirst and second start bits of the second set of binary indicators isset to a logical one; and the other of the first and second start bitsof the second set of binary indicators is set to a logical zero.
 3. Themethod of claim 1 wherein: the word length for each of the first set andsecond set of binary indicators is defined by a first start bit and aplurality of data bits; the start bit is set equal to the first data bitfor the first set of binary indicators; the remaining data bits for thefirst set of binary indicators alternate from the previous data bit; andthe start bit is set opposite to the first data bit for the second setof binary indicators.
 4. The method of claim 1 wherein: the word lengthfor each of the first set and second set of binary indicators is definedby a first start bit, a second start bit, a third start bit, and aplurality of data bits; each of the first, second, and third start bitsof the first set of binary indicators is set to a logical zero; and eachof the first, second, and third start bits of the second set of binaryindicators is set to a logical one.